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Old 04-28-2002, 04:26 AM   #1
DDMan
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Default Alternator Pulley...HOW THE HELL!?

DO YOU GET IT OFF!

I tried all night to get the damn thing off and i got nowhere. I'm begining to think that the alternator pulley means nothing and I'm not gonna deal with it unless It can be easily done. Its a 24mm bolt and well...with such a small pulley is hard to get enough grip to break the nut loose.

someone please help...I want to get these pulleys installed ASAP!
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Old 04-28-2002, 05:31 AM   #2
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DDMan,
Firstly, I wish you luck tackling this beast.

Secondly, RawCode has a good idea using multiple inserted stoppers to disperse an otherwise destructive method Here. But then there is the still the need for tremendous (herculean) torque to break the bond of this evil pulley. The bigger the breaker bar the better, I suppose.

Thirdly, It has been elsewhere advised to keep the belt in place and tightened to aid in immobilizing the pulleys whilst working on their nuts. I found this only partially effective because there was still slippage.

Fouthly, I failed and eventually had to bite the bullet and get it done at the shop....which in the end I wish I had done from the beginning.

Hope that helps. Again, good luck.

Ken

Last edited by Dr Ken; 04-28-2002 at 05:40 AM.
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Old 04-28-2002, 05:46 AM   #3
DDMan
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Default AHHHH (Pulling hair out over pulleys)

Ok, I have no air tools, so thats not an option.

That STUPID CRANK PULLEY wont come off! I have broken 2 breaker bars (duh!) and now am in search of something that will work.

I'm doing this alone, and have a rake holding down the brake pedal while I do this...and no matter what, its not coming off. Did any of you have to stand ON the car to get this bitch off?

I am seriously about to go out, get a craftsman socket wrench, and then put a 4' bar (1/4" thick steel pipe) over it and PULL!....At least if I break something it will probly be the craftsman stuff, and thats got a lifetime warranty!

AHHH, 3 hours and only have the DAMN P/S pulley on!

I PRAY the ALK isnt this hard!
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Old 04-28-2002, 06:49 AM   #4
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I used the handle from my 2 1/2 ton floor jack (~3') over a 2' breaker bar to get pulley bolts off. Worked on 4 I've swapped out. Is this a manual car I hope? Put the car in 4th gear, chock the front wheels in front of the tires and get someone to step on the brake. If it's an auto you will need to get a strap wrench to put on the pulley to hold it from turning. Never did an auto myself
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Old 04-28-2002, 07:57 AM   #5
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If you are brave, you can try the starter method..

Pull the spark plugs. Brace a breaker bar (not a socket) against the ground or the frame (beware of damage!). Crank the starter and watch what happends.

BTW the engine spins clockwise.

This is the method the local Subaru dealership mechanics use to take off pulley bolts on automatics... That or stick a pipe in the flexplate.
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Old 04-28-2002, 08:51 AM   #6
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Impact wrench gun. That's what I used to get ps and alternator pulleys off.
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Old 04-28-2002, 09:10 AM   #7
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Wait, I just read in your other topic about the crank pulley, and you said that you don't have an impact wrench gun. I didn't see any other way to take the nut/bolt off the pulley without using the impact wrench gun. There is no hole to put a screwdriver to keep the pulley in place on the alternator. You can probably use a strap wrench around the pulley and use a breaker bar to get the nut/bolt off instead.
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Old 04-28-2002, 09:49 AM   #8
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I used a chain wrench and a Giant breaker bar and 1 other person.
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Old 04-28-2002, 10:19 AM   #9
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Question

So it appears that you need a goodly amount of torque to get it
off, what kind of torque did you apply when you put it back on?

Stu.
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Old 04-28-2002, 10:25 AM   #10
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I say take a few steps if you havn't already.

Put the belts on.


Tighten the adjustments on the alternator and AC down nice and tight.I personally would pull the radiator to avoid damage to it.Its easy and only takes a 10 to 15 minutes.Then after all this is done,put the breaker nar on and instead of trying to pull on it give it some hard shoots with a hammer till it breaks loose.Mechanics use a impact wrench to loosen these bolts down which basically gives the same hammer effect.

I would NOT suggest this

"If you are brave, you can try the starter method..

Pull the spark plugs. Brace a breaker bar (not a socket) against the ground or the frame (beware of damage!). Crank the starter and watch what happends.

BTW the engine spins clockwise.

This is the method the local Subaru dealership mechanics use to take off pulley bolts on automatics... That or stick a pipe in the flexplate. "

Method
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Old 04-28-2002, 10:37 AM   #11
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> Pull the Radiator only takes 15 min

I think you may mean remove the fans, that only takes 15 min, pulling the radiator takes a lot longer, then you have to deal with putting back the coolant and purging the system of air. Removing the fans is a good idea. A few 10mm bolts on the top and then at the bottom at the right and left of the radiator are harness plugs for each fan to un plug. After you remove them put some cardboard (tape it there or something) on the back side of the radiator to avoid messing up the fins (and your hands)

I also agree with putting the belts back on that will help with resistance.

The starter thing is a very bad idea, sounds like you can do some major damage to life and limb not to mention the car.

FYI the crankshaft pulley bolt should be torqued to 90 - 100 ft lbs
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Old 04-28-2002, 10:40 AM   #12
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Quote:
Originally posted by Peaty
> Pull the Radiator only takes 15 min



FYI the crankshaft pulley bolt should be torqued to 90 - 100 ft lbs

Thanks Peaty. Similar torque for PS and Alt?

S.
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Old 04-28-2002, 10:43 AM   #13
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It took me 7 mis to remove.

Bottom hose,top hose,2 wire harness's for fans.

Its not hard and it gives you ALOT more room.It will take you 30 mins to remove the fans.
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Old 04-28-2002, 11:06 AM   #14
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Quote:
Originally posted by jetfan8178
It took me 7 mis to remove.

Bottom hose,top hose,2 wire harness's for fans.

Its not hard and it gives you ALOT more room.It will take you 30 mins to remove the fans.
I think there is plenty of room by just removing the fans myself. Yes removing the radiator isn't hard. It's getting it purged of air that is a PITA putting the coolant back. It's messy too. To properly purge the coolant system of air you are supposed to remove the two block plugs that are on the bottom of the motor. Those are very hard to remove. A lot harder than the pulley bolt (well almost) you need a 14mm allen wrench, good luck locating one. I drove all over creation trying to find on, I had to mail order mine. I know it may be possible to put back the coolant w/o opening those plugs but there have been posts from people not being able to get all the air out not doing that. If you get the motor air bound you risk damage to the motor big time. That is why I say just remove the fans and not the whole radiator. Even the Haynes manual (for the legacy but works the same on the impreza) says to only remove the fans when removing the crank pulley. They also say to use a chain wrench to lock the pulley in place.

I can't find the torque for the other pulley's I'll keep looking but 90-100 sounds high for those.
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Old 04-28-2002, 03:50 PM   #15
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GRRRR!

Still not working with a 3' breaker bar....in 4th gear....brakes applied fully. The damn POS still wont come off!....this is a PITA.

There is one more thing I might try before ill just put everything back and wait for 2 damn weekends when Eddy can help me with his air tools!
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Old 04-28-2002, 03:57 PM   #16
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You still haven't tried my way.
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Old 04-28-2002, 04:11 PM   #17
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Actually, I did try it before, and on my FINAL try (before giving up) It WORKED!!!

Thanks, Jet! The rubber mallet 1/2 way up the breaker bar (while pulling and applying about 100 ft/lbs) finally cracked the bitch loose....

Now the pulley is off and I will reset the battery as soon as I press on the brakes to put the pulley back on


DAMN that was a PITA....should I put anyting on the bolt just incase I have to take if off???

Anti-sieze? Cuz I dont have any, and well....the car is undriveable right now.
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Old 04-28-2002, 04:21 PM   #18
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Keep the alternator in the car with the belts hooked up. Have someone with some strength and wiegt to them push on the most open part of the belt possible. This will help keep the pully from slipping. The best thing to use is definately an impact gun, but if you don't have one a long breaker bar will help. If you don't have a breaker bar just find a piece of pipe to slip over the end of your ratchet. The other thing you might try is hitting the end of your rathet with a hammer. The shock might help get things started.

Best of luck.
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Old 04-28-2002, 04:22 PM   #19
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Sorry about the spelling, I was in a hurry.
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Old 04-28-2002, 05:19 PM   #20
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No dont put anything on it.Just give it a nice hammer shot when you tighten it down again.
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Old 04-28-2002, 06:49 PM   #21
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Glad you were able to get that pulley off without having to resort to the "starter" method..

The stock pulley gets torqued to 120 ft-lbs.. Aluminum pullies should only be torqued to 90 ft-lbs.

---

Hey Peaty, wanna elaborate on those plugs in the block. I'm pretty sure you ment the plugs in the BACK of the block and not the bottom. Shouldn't running the engine remove any air bubbles in the system.
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Old 04-28-2002, 07:41 PM   #22
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impact wrench.,..enough said
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Old 04-28-2002, 07:45 PM   #23
DDMan
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Default WooHoo!

I have a torque wrench that goes to a max of 75 ft/lbs, and i actually used a socket with breaker bar over it to tighten it. then I made sure it was over 75 ft/lbs with the torque wrench....it was and probly set to a good 100 ft/lbs.


On a preformance note, I reset the ECU and then took it out on a drive (after letting it properly warm up). Its ALOT easier to downshift, and the revs seem to go up quicker. Seems to make alot more difference in 3rd gear than 1st and 2nd.
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Old 04-28-2002, 08:43 PM   #24
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I remember watching Shiv and Alex loosen the pulley bolt using the starter method. I backed the HELL away from that mess. It worked though, in a snap (a scary snap but a snap none the less).

I did mine myself...and it was dificult but not impossible. On a scale of 1-10...10 being the most PITA install...I'd give it a 7. Tranny mount was a 1, trunk light was a 0.5. Leda's (before I discovered that my control arm was bent) has been a 15,000,000. I could probably swap suspension with my eyes closed by this point. But all in all I have to say most of the things I have done to the car have been fairly easy...I LOVE Subaru for that.

NC
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Old 04-29-2002, 08:43 AM   #25
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i did them myself as well (with a friend to help with crank pulley) but i also was puzzled by the alternator pulley at first.

go here to see what i did. i posted pictures as well.

hope that helps. it helped with the other guy
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